Contact fracture of full-ceramic crowns subjected to occlusal loads

Abstract The mechanisms contributing to failure of full dental ceramic crowns under occlusal loads were studied using a unique optical approach. Model specimens comprising triple-layered crowns (veneer, core and substrate) were developed with both flat and curved occlusal surfaces and then subjected to simulated quasi-static occlusal loading using a spherical indenter. Deformation within the specimens during loading was analyzed by means of digital image correlation (DIC). Finite element models were also developed and used to examine the mechanics of contact. Results of the experiments with flat dental crowns indicated three typical modes of failure, i.e. cone cracks, plastic yielding and radial cracks. Fracture of the specimens with curved dental crowns was complicated by contributions from competing and multiple modes of failure. Both experimental and numerical results conclude that the dominant fracture mode in the full-ceramic crowns was radial cracking in the core beneath the contact area. However, displacement fields obtained using DIC showed that debonding developed near the shoulder of the crown, particularly during off-axis loading, and initiated under substantially lower occlusal loads than those required for crack initiation.